Making concrete foundation piers and the like



Nov. 23 192:6.'

M. M. UPSON MAKING CONCRETE FOUNDATION PIES AND THE LIKE Filed Mav l1 1923 2 Sheets-Sheet l Nov. 23 1926.v

M. M. UPSON MAKING CONCRETE FOUNDATION NIEHS AND THE LIKE Filed Mav 11. 1923 2 Sheets-Sheet 2 Snom/01 /laxwel/ M 0,0500

p Patented Nov. 23, L92". Unirse strates PATENT OFFICE.

MAXEL'L M. USSN, OF ENGLEVJGOD, NElW JERSEY, ASSIGNOR T0 CHARLESB. GOW GOMEANY, 0F BOSTON, MASSACHUSETTS, A CORPORATION 0F MASSACHUSETTS.

MAKNG CONCRETE FOUNDATIGN PIERS AND THE LIKE.

Application led May 11, 1923. Serial No. 638,155".

This invention relates to the construction son and air is pumped into and througl'iV the or formation of concrete columns, piers and latter, to a pressure suiiicient to keep water `the like in the ground, for foundations and in undue amount out of the caisson,and the other purposes, and its chief object is Vto hole is deepened by excavating under the provide a Simple and effective method by latter. Preferably the caisson is lowered or so which such piers, of the necessary strength pressed down through the hole, intoA the and bearing capacity,y can be constructed at ground, keeping pace with the excavation. low cost in earth which is in part drT and `When rock 0r hard bearing materialV is -in other parts saturated with or contains reached or approached near enough ay layer l0 water in such amount as to cause excessive of concrete is deposited thereon, of: suifir inflow or seepage into the excavation. In cient thickness to seal` the lower end of the carrying out the invention in the preferred Caisson against excessive inflow after the manner the shaft in which the concrete pier air pressure is relieved.` TWhen the concrete is to be cast is begun by sinking, through has set hard enough to serve the purpose each other into the ground, a series of conindicated the air lock can be removed. The 'zu centric steel shells of successively smaller hOle iS then filled with concrete and aszthe diameter; the largest being sunk first, then filling rises in' the upperlined portion of the the next largest inside of the first, and so on hole the Shells forming the lining thereof through the dry 01" non-Waterbearng' part Li-Fe Withdrawn. OIlQ after the other OI' le- 20 of the ground. After each shell is driven, use. l

and before the next is sunk, the soil en- The method outlined above is illustrated (31059@ by the driven Shell is removed, S0 1D VlllOuS SELgGSfiIl the ICCOIIlpLIlyillgCllaW- that 'a hole is produced lined with steel HgS, in Whichwhich effectually prevents caving or slip- Fig. l is a` section showing the lined hole and therefore permits working close to produced by sinking the steel shells, before e .sting foundations and buildings without the caisson is put iny place; Y injury thereto. As will appear more `fully Fig. 2 is a section showing thecaisson and hereinafter, these shells constitute a tempoair lock in position, ready for the deepening rary lining for the upper and naturally dry of the hole to rock or other hard bearing portion of the hole. Vhen the waterbearing material; f 85 material is reached or approached (as may Fig. 3 is a detail section illustrating a be known by seepage or by previous sinkcaisson provided withan enlarged' or thick.- ings or boring-s) the sinking of the casing cned lower end. to form a better cuttingedge shells ceases, and in the hole a concretecyland decrease the friction on the outside of inder or caisson is placed, preferably fitting the caisson `as the latter descends 90 the lowermost shell closely enough to pre- Fig. i is. a section showing the excavation' vent excessive seepage outside of the caisson coinpleted,y the caisson sunk to rock', the into the lined upper portion of the hole as concrete seal cast in the lowerl end of the the caisson is sunk through the waterbearing caisson, andk the air lock` removed strata. The concrete cylinder, as will ap- F ig. 5 is a. section showing the hole: par- 95 pear more fully hereinafter, serves also as a tially iilledwith concrete. This' figure also permanent lining for the hole at the point illustrates the provision of an enlarged footwhere such a lining` is necessary or desirable. ingA below the caisson. The cylinder may be cast in the hole, using Fig. 6r is a detail section illustrating' -a be cast outside and inserted into the hole. ground or holding it down against the liftln most eases the caisson is ofsuch length ing` effort of the air pressure. Y

that when sunk to rock or hard bearing ma- Fig. 7 is a section of the lower portion terial its upper end will still be in the lined of the forms which may be used'whenia1 caislower-most shell, to continue to exclude eX- As indicated'inV the drawings, the: steel cessive seepage or inflow of water during shells 10, 1l, 12,18, ofany suitablesize the filling?,- of the hole with concrete. and preferably cylindrical in form,- are of rllhe caisson having been established in the successively smaller diameter so that one lined hole, an air lock is placed .in the csiscandescend through the other. The largest 110 suit-able forms for the Juraose or it ma method of Dressing the caisson into the 100 l e e portion of the hole, say far enough up in the son is to be cast within a hole. 105

the the is rst driven or otherwise sunk in ground, followed by the others in order, soil in the last driven being removed before the next is sunk. F our such shells are shown, but of course the exact number is immaterial and depends upon the length of the individual sections or shells and the depth at which inflow or seepage becomes or would become excessive, When such point is reached (as in Fig. l, for example) the sinking of the lining shells ceases, and a hollow concrete cylinder or caisson la is established in thelined hole, as in Fig. 2. This caisson may be cast in one piece of the necessary length, or its` length may be in creased as the work progresses by casting or fitting additional sections on top. As in dicative of this method I have shown the reinforcing bars or members l5 extending above the top edge of the caisson in Fig. 2. As previously stated, the concrete caisson should fit the lowermost shell, lO, snugly enough to insure against excessive seepage or inflow up around the outside of the caisson and into the shell-lined part of the hole. An air lock, indicated diagrammatically at i6, is now placed in the caisson and adequate air pressure applied therethrough, aft-er which the hole is deepened by excavating inside of the caisson. As the worl proceeds, the caisson descends, forming a rigid and substantial lining which prevents caving or collapse of the walls of the hole and permitting the excavation to be carried on rapidly and safely. To facilitate the `downward progress of the caisson the lower end thereof may be beveled, as in Ifig. 2, for example. Preferably the lower end is provided with an enlargement, as indicated at 17, Figs. 3, a and 5, to form a strong and substantial edge, and also to make the hole (as the caisson descends) slightly larger in diameter than the body of the caisson and thereby diminish the :tric- `tion on the sides of the latter in its downward movement. rlhis enlarged or thickn ened edge can be provided in any convenient way. For example, on a caisson which is cast in place, it can be produced by suitable shaping of the hole below the lowest shell, 10; or, if the caisson is made outside and inserted in the hole, the enlarged lower edge can be cast on to it in the same man ner, or the lower edge of the caisson may be banded with sheet metal, not shown, secured to the concrete by any convenient means.

When roclr or other hard bearing material I8, Fig. Il, is reached, the lower end of the caisson is sealed or closed,'as by means ofa mass of concrete 19 deposited on the rock in sufficient amount to extend well up into the caisson and allowed to set firmly enough to seal the bottom of the hole against undue seepage or inflow. rlhe air pressure can then be relieved and the air lock removed. I now have a lined hole, eX- tending down to rock or hard bearing material as in Fig. Il, and at least dry enough to permit the rest of the work to be carried out in the open air.

The hole is new filled with concrete. llfhen the filling reaches or approaches the top of the permanent lining (which, itwill be understood, is left in place) the lowermost steel shell lO is pulled out and the filling continued to the next shell, ll, which is then pulled and the filling continued, and so on to the top. In some situations, as for example where excessive lateral pressures are encountered, it may be necessary to let the successive fillings set firmly enough to resist such pressure before pulling the shell nent above. In this way it is possible to remove all the shells under conditions which would otherwise make such course dangerous if not impossible.

If desired, the lower end of the concrete column can be provided with an enlarged footing, to afford larger bearing surface, thereby distributing the total load and decreasing the load per unit area. Such a belled or enlarged end is shown in Fig. 5, and may be produced by suitable enlarge ment of the hole below the caisson, the descent of which is arrested at a suitable point above the rock, 18. The initial body of concrete, for the seal i9, is then deposited in sufficient amount to lill the enlarged excavation and extend up into the caisson.

It is not always necessary to establish the caisson in the shell-lined hole as soon as water-bearing material is reached. ln fact it frequently happens that the shells can be driven through a water-bearing stratum and the water cut olf thereby, permit ig excavation to be continued beyond. in the open air, until material is reached which carries so much water that it cannot be excluded by the shells alone.

In some situations the liftingl effort of the air pressure in the caisson may, at depths of more than, say, twenty-live feet or so, be sufficient to overcome the total weight of the caisson and air lock and thus arrest or prevent desceue of the caisson. In such cases I prefer to utilize the friction of one or more. of the steel lining shells against the arth to press the caisson down into the ground. For this purpose I may provide a suitable number of standards 2() around the outside of the caisson, at the top thereof. and fasten them removably to an appropriate shell or shells, in the present instance the shells l2 and i3, as by a lug-and-slot construction. not shown.

Each standard is provided with a vertically adjustable shelf 2l, extcruli'ngl inwardly to serve as an abutment for a screw jack Q2, by which the necessary downward pressure can be exerted on the caisson.

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l/V hen the maximum travel of the jack is reached. the abutment shelf is lowered on the standard and the operation continued. I have shown only one standard, shelf, and jack, but two or more should be used, spaced around the caisson, to keep the latter straight and moving evenly.

As stated above, the caisson or traveling lining cylinder may be cast outside of the hole, or inside of the same. rl`he latter course is, in some cases at least, preferable, as-it keeps the working area above ground iree for more economical carrying on ol the construction job. For casting the caisson in the hole, l may use sheet steel forms, as in Fig. 7, for example, in which 23 and designate inner and outer forms providing an annular space between them to receive the concrete. The lower form 253 fits into the lining shell l0 and the upper forms are superposed one on the other. The lower form 24 may rest directly' on the ground,l which is shown enlarged to provide the thickened cutting edge 17 Fig. 3 or greater diameter than the shell l0. The forms of either or both series may be split longitudinally, as indicated at 25 and 26, to facilitate removal after the concrete has set. lf the sheet metal of which the l'orms are made is not still enough to prevent distortion during the casting any convenient means, not shown, may be used outside of the outer series 23 and inside of the inner series 24 to hold them in shape. In most cases it is desirable to cast the entire caisson at one operation, as this method avoids the necessity oi interrupting the work of excavation to permit lengthening the caisson by casting additional sections thereon.

It is to be understood that the operations described in the foregoing constitute the preferred practise but that the invention can be carried out in other ways without departure from its spirit as delined by the following claims.

I olaiml. In a method of forming concrete piers and the like in situ, sinking into the ground, through each other in succession, a series ot concentric shells of successively smaller diameter and removing the soil from the shells as the sinking thereof proceeds, to produce a hole having a lining capable of preventing caving and slipping due to lateral pressure;

` establishing in the shell-lined hole thus produced a downwardly movable permanent lining section oi concrete and applying air pressure therethrough to prevent excessive seepage or inflow oi" water from below; excavatinginside the permanent lining section to deepen the hole. and as the deepening proceeds moving the permanent lining section downwardly to prevent caving and undue seepage in later stages, until the desired depth has been reached; sealing the lower endl` of the permanent lining section to permit relievingthe air ressure without cans ing excessive seepage or inliow; filling the hole above such seal withl concrete, and as the filling rises in the shell-lined portion of the hole, withdrawing the shells in succession. v

ln a method of forming concrete piers and the like in situ, sinking intor ground, through each other in succession, a seriesv ont `concentric shells of successively smaller diameter and, removing the soil 'trom the shells as the sinking thereoiI proceeds; casting in the lined hole thus produced a concrete permanent lining section adapted to move downwardly through the shell of smallest diameter to form a pern'ianent lining lier a lower portion ofthe hole; applying air pressure through the permanent lining section to prevent excessive inflow or seepage irom. below; deepening the hole below the shells by excavating' inside of the caisson, and as the excavation proceeds, movin@- the permanent lining section downwardly to prevent caving or collapse ol the walls of the hole; sealing the lower end ol the permanent lining section under air pressure; then filling the permanent lining section and the shell-lined portion of the hole with' concrete in the open air, and as the filling rises inthe shell-lined i portion withdrawing the shells in succession. 3. In a method or' forming concrete piers and the like in situ, sinking intothe ground,

through each other in succession, a series oi concentric shells of successively smaller diameter and removing the soil from. the shells as the sinking thereof proceeds.; casting in the lined hole thus produced a permanent concrete lining caisson adapted to move downwardly through the shell of smallest diameter; applying air pressure through the caisson to prevent excessive inliow ory seepage from below; deepening the hole below the shells under said air pressure by excavating inside of the caisson, and as the excavation proceeds, moving the caisson downwardly to prevent caving or collapse of the walls of the hole; and sealing the lower end ol the caisson under air pressure to permit relieving the air pressure and'illing the hole with concrete in the open air without exces sive inflow or seepage from below.

4. In a method of forming concrete piers and the like in situ, sinking into the ground, through each other in succession, a series of removable concentricv shells of successively smaller diameter and removing the soil from the shells as the sinking `thereof proceeds; casting in the temporarily lined hole thus produced a pern'ianent concrete lining caisson adapted to move downwardly through the shell or smallest diameter and providing the caisson with a cutting edge ot greater diameter, than said Shell to facilitate the descent oix the caisson;

applying air pressure through the caisson to prevent excessive inflow or seepage from below; deepening the hole below the shells by excavating inside ot the caisson, and as the excavation proceeds, moving the caisson downwardly to prevent caving or collapse of the walls of the hole; and sealing the lower end of the caisson under air pressure to permit the air pressure to be relieved without causing undue inflow or seepage into the caissonV from below whereby the concrete to form the pier can be deposited in the open air.

5. ln a method of forming concrete piers and the like in situ, producing in the ground a hole having a lining composed ot' removable concentric shells of successively smaller diameters, establishing in such temporarily lined hole a permanent lining caisson adapted to move downwardly through the shell ont smallest diameter, deepening the hole below the shells by excavating inside of the caisson while preventing excessive inflow or seepage into the latter from below and as "la deepening proceeds moving the caisson downwardly toserve as a lining for the lower portion ot the hole, and sealing the lower end ot the caisson, to provide a substantially dry hole t'or casting the concrete pier, lined in 1 t with the concentric shells and in part with the caisson.

6. In a method ot i'orming concrete piers and the like in situ, producing in the ground a hole h ving a lining composed ot removable concentric shells ot successively smaller diameters, establishing in such temporarily lined hole a permanent lining caisson adapted to move downwardly through the shell or' smallest diameter, deepening the hole below theshells by excavating insioe ot' the caisson while preventing excessive inflow or seepage into the latter lrom below, and as the deepening proceeds moving the caisson downwardly to serve as a lining for the lower portion of the hole.

7 In a method or forming concrete piers and the lil-:e in situ, sinlring into the ground, through each other in succession, a series ot removable concentric shells and removing the soil from the shells as the sinking thereof proceeds to produce a hole having a temporary lining; establishing in the hole a permarientlining section in the form ot a concrete caisson movable downwardly through the lowermost of the removable shells; deepening the hole by excavating below the lining caisson, and causing the latter to descend to form a permanent lining` for the hole below the shells; sealing the bottom of the germanent lining section to prevent excessive seepage and inflow or water; and thereafter lilling the hole with concrete and withdrawing the removable shells.

8. In a method ot forming concrete piers Lil and the lilre in situ, sinking into the ground,

through each other in succession, a series of removable concentric shells and removing the soil from the shells as the sinking thereof proceeds to produce a hole having a temporary lining; establishing in the hole a permanent lining section in the iorm or a concrete caisson movable downwardly through the lower-most of the removable shells; deep- @ning the hole by excavating below the lining caisson, and causing the latter to descend to form a permanent lining for the hole below the shells; enlarging the hole laterbelow the caisson; lilling the enlarged portion of the hole and the bottom ot the pern'ianent lining section with concrete to seal the latter and provide an enlarged footing tor the pier; and thereafter filling the hole with concrete and withdrawing the removable shells.

Sl. 'lhe method of forming concrete piers and the like in situ and under substantially normal atmospheric pressure conditions comprising, sinking into the ground, through each other and in succession, a series of concentric shells ot successively smaller diameter and removing the soil within the limits of the shells as the sinking thereoic proceeds to produce a hole whose depth extends to limits where water seepage renders excavating to a lower depth impracticable without the use et compressed air; establishing in the shell-lined hole thus produced a lining setion otl concrete whose outer' dimension is less than the inner dimension oi vthe last shell to be positioned; applying air pressure witl said section; excavating inside the concrete lining section to deepen the hole, and, as the deepening proceeds, moving` the concrete lining section downwardly to maintai` the hole open; sealing the lower end ot the concrete lining section to permit relievthe air pressure without allowing excessive seepage or inflow; removing the air pressure from within the closed confine ot the concrete lining section; and h'lling the hole under substantially normal atn'iospheric pressure conditions.

l0. The method ol forming concrete piers a d the like in situ and under substantially normal atmospheric pressure conditions coniprising, sinking into the ground, through each other and in succession, a series ot concentric shells of successively smaller dia-meter and removing the soil within the limits of the shells as the sinkingv thereof proceeds, to produce a hole whose depth eX-v tends to limits where water seepage renders excavating to a lower depth impracticable without the use of compressed air; establishing in the shell-lined hole thus produced a lining section oi' concrete adapted to lit within the area or` the lower-most shell and being of a length sutlicient to extend 'from the lower-most shell to hard bearing material; applying air pressure within said section;

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excavating within the concrete lining to deepen the hole and cause the concrete lin ing to move downwardly; sealing the end of the concrete lining section when the hole has been excavated to the desired extent; relieving the closed contines of the concrete lining section from air pressure; and casting a pier under substantially normal atmospheric pressure by filling the entire extent of the opening produced by excavating.

11. The method of forming concrete piers and the like in situ and under substantially normal atmospheric pressure conditions comprising, producing in theI ground a hole having a lining comprising successive shells; deepening this hole by the addition of shells and additional excavation to a depth where deeper excavating is impracticable Without the use of compressed air; establishing a single caisson within said hole adapted to be lowered to a depth desired and having sulicicnt length to extend from the loWer most casing to the depth desired; establishing within said caisson air pressure; lowering the caisson by excavating to the depth desired; sealing the lower end ol said caisson to maintain the hole dry when the air pressure is relieved; relieving the air pressure from within the caisson; and lilling the hole under normal pressure conditions.

In testimony whereof I hereto aliix ymy signature.

MAXWELL M. UPSONe 

